Architectural Building Material

ABSTRACT

An architectural material comprising a bulk polymeric foam material which includes additional structural support which provides increased strength and durability at the front surface of the architectural material. The architectural material includes a mesh material which is disposed near the front surface of the architectural material. The architectural material may additionally include a barrier layer which further protects the surface of the architectural material.

FIELD OF THE INVENTION

The present invention generally relates to architectural building materials. More particularly, the present invention relates to architectural building materials having a natural appearance.

BACKGROUND

Natural materials such as stone, wood, cement and brick are popular for use on the interior and exterior of buildings, particularly for architectural applications. Such materials may be used as moldings, wall coverings, railings, pillars, facades and other interior and exterior details. Natural materials, however, can be expensive and difficult to install. Natural materials, such as stone, can be very heavy which can limit their application or require the use of additional structural support. Molded cement pieces similarly require additional support when used as for such applications. Furthermore, natural materials, such as wood, may degrade over time and require periodic replacement and or treatment.

Due to some of the problems associated with natural materials for architectural applications, artificial materials have been created which can be molded to have the appearance of natural materials such as wood, stone, brick, and cement. Such materials may be molded into any type form and have the appearance of stone, concrete, brick, and wood. Examples of polymeric materials include polyurethane foam, polystyrene foam, and polyethylene foam. The artificial materials are lightweight and can be formed into any shape and/or size while having the appearance of natural materials. The weight of the materials allows the artificial pieces to be easily installed without the need for any additional structural support. The artificial materials are also very durable and can withstand fading over time. Furthermore, artificial materials are much more inexpensive than natural materials.

Artificial materials, however, may not be as durable and strong as natural materials with respect to resisting attack from birds and rodents. Birds and rodents may be able to easily destroy such materials as compared natural materials such as stone, cement, and brick. For instance, birds such as woodpeckers have a much easier time digging into artificial materials as compared to stone or cement counterparts. Also, artificial materials may be easily chipped or deformed when contacted forcefully by inanimate objects, such as sticks, branches, poles, tools, etc. As such, there is a need in the art for artificial architectural materials having increased durability and strength to resist attack from birds and rodents and forceful contact from inanimate objects.

SUMMARY OF THE INVENTION

Disclosed herein, is an architectural material comprising a bulk polymeric foam material and a mesh material disposed within the polymeric material. The mesh material may be disposed within the polymeric foam material at a position between the midpoint and the front surface of the architectural material. The mesh material may be disposed proximate to the front surface of the architectural material. The mesh material is preferably disposed within 3 cm from the front surface of the architectural material. More preferably, the mesh material may be disposed within 2 cm from the front surface of the architectural material. Most preferably, the mesh material is disposed within 1 cm from the front surface of the architectural material.

The architectural material may further comprise a barrier layer. The barrier layer may be formed from a gel-based precursor material, a liquid based precursor material, or a powder based precursor material. The mesh material may be at least partially disposed within the barrier layer. The architectural material may also comprise a topcoat layer which may be applied on the barrier layer or the polymeric foam material.

The polymeric foam material may be comprised of polyurethane free rise foam. The polyurethane free rise foam may have a density in the range of 2 pounds per cubic feet to about 25 pounds per cubic feet. Preferably, the polyurethane free rise foam may have a density in the range of 8 pounds per cubic feet to about 14 pounds per cubic feet.

The mesh material may comprise metal, composite material, polymer material, fiberglass, or any combination thereof. Preferably, the mesh material comprises a polymer coated fiberglass material.

Also disclosed herein is a method for forming an architectural material in a mold. The method may comprise the steps of 1) placing a mesh material in the mold proximate to the inner surface of the mold cavity, 2) dispensing a polymeric foam precursor material into the mold cavity, 3) sealing the mold, 5) placing the mold into a press, and 6) removing the architectural material from the mold. The method may further comprise the step of applying a barrier precursor material to the inner surface of the cavity of the mold prior to placing the mesh material into the mold. The method may also comprise the step of applying a topcoat layer to the architectural material when removed from the mold.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1, is a depiction of an architectural material in accordance with the present invention.

FIG. 2, is a depiction of an architectural material including a barrier layer in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

In accordance with the present invention there is provided an architectural material having increased strength and durability. The architectural material has increased strength and durability at the front surface of the architectural material to increase resistance to attack from birds, rodents, insects and other creatures while maintaining a decorative face. The increased strength and durability at the surface of the material further prevents damage to the material which may be caused from forceful contact with inanimate objects or exposure to inclement weather.

A depiction of an architectural material in accordance with the present invention is shown in FIG. 1. The architectural material 10 generally comprises a bulk material layer 20 and a mesh material 30. The bulk material layer 20 generally comprises a high density polymeric foam material. The mesh material 30 may be disposed within the bulk material layer 20. Preferably, the mesh material is disposed in the bulk layer at a position between the midpoint and the front surface of the architectural material. The midpoint of the architectural material 10 is defined herein as a point within the architectural material that is halfway between the front surface 40 of the architectural material and the portion of the back surface 50 of the architectural material furthest from the front surface of the architectural material. The back surface 50 of the architectural material is defined herein as the surface opposite the front surface of the architectural material. More preferably, the mesh material 30 is disposed within the bulk material layer 20 proximate to the front surface 40 of the architectural material. The mesh material being disposed proximate to the front surface of the architectural material provides increased durability and strength to the front surface of the architectural material. Specifically, the mesh material may be disposed within 3 cm from the front surface of the architectural material. More preferably, the mesh material may be disposed within 2 cm from the front surface of the architectural material. Most preferably, the mesh material may be disposed within 1 cm from the front surface of the architectural material.

The architectural material may further comprise a barrier layer as depicted in FIG. 2. The barrier layer 60 may be a thin layer disposed on the front surface 40 of the architectural material 10. The barrier layer 60 is located adjacent to the bulk layer 20 such that the barrier layer 60 coats the surface of the bulk layer 20. The barrier layer may provide the color and appearance of the architectural material 101. The barrier layer may also protect the architectural material from weathering and/or fading. Alternatively to being disposed within the bulk layer, the mesh material may be disposed in the barrier layer or at the transition between the bulk layer and the barrier layer.

The bulk layer 20 generally comprises a high density polymeric foam material. Examples of polymeric foam materials are polyurethane foam, polyethylene foam, and polystyrene foam. Polyurethane foam is the preferred material for the bulk layer of the architectural material. Polyurethane foam material has a fast cure rate which enables finished parts to be produced after cooling in two to fifteen minutes. While polyurethane foam is the preferred embodiment of the present invention, any type polymeric foam material may be used in accordance with the present invention.

The polyurethane foam may be formed by mixing a first component A with a second component B. When mixed, component A and component B react exothermically to form a polyurethane foam. The final density of the polyurethane foam can be controlled by modifying the starting materials and/or modifying the amount of material placed into the mold. The polyurethane foam in the bulk layer nay have a density in the range of 2 pounds per cubic feet to about 25 pounds per cubic feet. Preferably, the density of the polyurethane foam is in the range of 8 pounds per cubic feet to about 14 pounds per cubic feet.

The first component A is a resin component generally containing one or more polyols and the second component B is a material containing one or more isocyanate compounds. Component A and component B may be mixed in a ratio of 1:1 by volume. The ratio of component A to component B may vary from 1:10 to 10:1. Preferably, the amount by volume of component A is greater than the amount by volume of component B. This ensures complete reaction of all component B (isocyanate material).

The first component A may generally comprise a polyether polyol blend. Examples of polyol compounds include any difunctional or polyfunctional hydroxyl compounds having a molecular weight below about 1800 such as, 1,2- and 1,3-propylene glycol; 1,4- and 2,3-butylene glycol; 1,6-hexane diol; 1,8-octane diol; neopentyl glycol; cyclohexane dimethanol (1,4-bis-hydroxy-methyl cyclohexane); 2-methyl-1,3-propane diol; glycerol; trimethylol propane; 1,2,6-hexane triol; 1,2,4-butane triol; trimethylolethane; pentaerythritol; quinitol; mannitol and sorbitol; methyl glycoside; diethylene glycol; triethylene glycol; tetraethylene glycol; polyethylene glycols; dipropylene glycol; dibutylene glycol and polybutylene glycols.

The first component A may additionally include one or more blowing agents and/or catalytic agents. Blowing agents may be used to tailor the cellular structure of the polyurethane foam. The catalytic agents may be used to help the reaction between component A and component B progress and/or aid the final curing process of the material. The first component may also include one or more structural additives which increase the rigidity and strength of the material. Such additives may include fiberglass, cementitiuos materials, and other type filler materials. To provide color and varied surfaces to the architectural material, colorants, dispersion dyes and pigments may be added to component A. To reduce ultraviolet oxidation and enhance weathering anti-oxidation and ultraviolet adsorber additives may also be included in component A.

The second component B is generally an isocyanate material. In particular, the isocyanate material may be polymeric diphenylmethane diisocyanate. Examples of other conventional isocyanates that may be included in component B include organic aromatic and aliphatic polyisocyanates or mixtures thereof. Organic aromatic polyisocyanates for example may be 2,4-toluenediisocyanate, 2,6-toluenediisocyanate, p-phenylene diisocyanate, naphthalene diisocyanate, polymethylene polyphenyl isocyanates, 1,6-hexamethylene diisocyanate, 1,4-cyclohexyl diisocyanate, 1,4-bis isocyanoctomethyl-cyclohexane and mixtures thereof.

The mesh material 30 may be any type mesh material formed from polymer materials, composite materials, fiberglass, metal, or any combination thereof. Preferably the mesh material is a polymer coated fiberglass mesh. An example of polymer coated fiberglass mesh is 921 Sto Armor Mat from Sto Corporation. Any size mesh may be used in accordance with the present invention. Preferably the size of the mesh is in the range of 0.0625 inches to 0.5 inches. More preferably, the size of the mesh is in the range of 0.125 to 0.25 inches. The mesh material may be flexible or rigid. The thickness of the mesh material may vary so as to provide the desired flexibility or rigidity of the mesh material. The thickness of the mesh material may be in the range of 0.0625 inches to 0.025 inches. Preferably, the mesh is able to conform to the shape of the front surface of the architectural material. The area of the mesh material is preferably approximate to the area of the front surface of the architectural material such that the mesh material and the front surface of the architectural material have similar lengths and widths. This allows the mesh material to be positioned along the entire length and width of the front surface of the architectural material.

The barrier layer 60 is generally comprised of a protective coating which is applied onto the surface of the architectural material. The barrier layer may have a density higher than the bulk layer material. The barrier layer may be applied onto the inner surface of a mold prior to introduction of the bulk layer material into the mold. When applied onto the inner surface of the mold cavity, the precursor material is preferably fully cured before the bulk layer material is introduced into the mold cavity. Introducing the bulk material into the mold cavity when the barrier material is not fully cured may result in formation of weak area in the architectural material. The barrier layer may also be applied onto the surface of the architectural material upon removal from the mold.

The barrier layer may be formed from a precursor material in liquid or gel form. The gel or liquid precursor material may be water or solvent based. Once dry, the precursor gel or liquid material forms the barrier layer on the architectural material. The barrier layer may include pigments which provide the desired color to the architectural material. The barrier layer may also include additives which protect the architectural material from weathering and fading. An example of a gel-type material that may be utilized as the barrier layer is a modified wollostanite mineral fiber-reinforced polyester gel coat material. Such material is applied onto the surface of a mold and cured prior to addition of the polyurethane foam precursor components. An example of a liquid material an acrylic barrier coating. A specific type of acrylic barrier coating may be WB White Barrier Coating as supplied from Berkley Products Company of Akron, Pa. Such materials may provide excellent chip resistance to the architectural material while providing an aesthetically appealing surface.

The barrier layer may also be formed from a powdered material. The powdered material may be applied to the mold cavity prior to introducing the bulk layer material into the mold. The powdered material may remain in powder form prior to the polyurethane material being introduced into the mold cavity. Alternatively, the powdered material may be wetted with water or solvent based liquid prior to the polyurethane material being introduced into the mold cavity to form a precursor material as previously described. When wetted, the precursor material is preferably allowed to cure prior to the bulk material being introduced to the mold cavity.

The architectural material may further include a top coat material. The topcoat is generally applied on top of the barrier coat. When a barrier layer is not used, the topcoat may be applied directly onto the bulk layer. The topcoat may be selected from any type of paint, either latex or oil based. Preferably, the topcoat is a latex based exterior grade paint. The topcoat may also be selected from any type of protective coatings.

A high density polyurethane foam architectural material in accordance with the present invention may be formed via a molding process. The mold cavity used in the molding process may be any type mold cavity typically used to cast polymeric foam materials. Preferably, the mold cavity is formed from a polymeric silicone material which has rigid structural support. Prior to a mixture of component A and component B being introduced into the mold cavity, the mold cavity may be treated with a mold release agent to aid in removal of the finished part from the mold.

When forming the architectural material, the mesh material is first placed into the mold cavity. If a barrier layer is included in the architectural material, a precursor barrier material may be applied onto the inner surface of the mold cavity prior to the mesh material being placed in the mold. The precursor barrier material may be cured, partially cured, or uncured prior to the mixture of component A and component B being introduced into the mold. To hold the mesh material in place and to ensure its placement proximate to the front surface of the architectural material, the mesh material may be adhered to the precursor barrier material, and/or held into place via one or more structural supports. The structural supports may be selected from pins, tacks, staples, clips, and the like.

Once the mesh material is placed in the mold, component A and component B are mixed and subsequently dispersed into a mold cavity where component A and component B react to form a high density polyurethane foam. Once component A, component B, and the mesh material are placed into the mold, the mold cavity is seated such that the reaction product, the polyurethane foam, expands and completely fills the mold cavity. The sealed mold cavity may then be placed into a press to prevent the polyurethane foam from expanding beyond the mold cavity. The mold is retained in the press from two to fifteen minutes which allows the polyurethane foam to cure and cool.

The density of the polyurethane foam may additionally be controlled by varying the amount of component A and component B placed into the mold cavity. The reaction between component A and component B is exothermic which provides heat that may be used to help fuse the barrier layer with the bulk layer of the architectural material.

While there have been described what are believed to be the preferred embodiments of the present invention, those skilled in the art will recognize that other and further changes and modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the true scope of the invention. 

1. An architectural material comprising: a bulk polymeric foam material; and a mesh material disposed within said polymeric material at a position between the midpoint and the front surface of said architectural material.
 2. The architectural material according to claim 1, wherein said mesh material is disposed proximate to the front surface of said architectural material.
 3. The architectural material according to claim 1, wherein said mesh material is disposed within 3 cm from the front surface of said architectural material.
 4. The architectural material according to claim 1, wherein said mesh material is disposed within 2 cm from the front surface of said architectural material.
 5. The architectural material according to claim 1, wherein said mesh material is disposed within 1 cm from the front surface of said architectural material.
 6. The architectural material according to claim 1 further comprising a barrier layer.
 7. The architectural material according to claim 6, wherein said barrier layer is formed from a gel-based precursor material, a liquid based precursor material, or a powder based precursor material.
 8. The architectural material according to claim 6, wherein said mesh material is at least partially disposed within said barrier layer.
 9. The architectural material according to claim 1, wherein said polymeric foam material is polyurethane free rise foam.
 10. The architectural material according to claim 9, wherein said polyurethane free rise foam has a density in the range of 2 pounds per cubic feet to about 25 pounds per cubic feet.
 11. The architectural material according to claim 9, wherein said polyurethane free rise foam has a density in the range of 8 pounds per cubic feet to about 14 pounds per cubic feet.
 12. The architectural material according to claim 1, wherein said mesh material comprises metal, composite material, polymer material, fiberglass, or any combination thereof.
 13. The architectural material according to claim 1, wherein said mesh material comprises a polymer coated fiberglass material.
 14. The architectural material according to claim 1, wherein said architectural material further comprises a topcoat layer.
 15. A method for forming an architectural material comprising the steps of: 1) applying a barrier precursor material to the inner surface of the cavity of a mold; 2) placing a mesh material in said mold proximate to the inner surface of the cavity of the mold; 3) dispensing a polymeric foam precursor material into the cavity of said mold; 4) sealing said mold; 5) placing said mold into a press; 6) removing said architectural material from said mold.
 16. The method according to claim 1 further comprising the step of: 7) applying a topcoat layer to said architectural material.
 17. A method for forming an architectural material comprising the steps of: 1) placing a mesh material in a mold proximate to the inner surface of the cavity of said mold; 2) dispensing a polymeric foam precursor material into the cavity of said mold; 3) sealing said mold; 4) placing said mold into a press; 5) removing said architectural material from said mold.
 18. The method according to claim 1 further comprising the step of: 6) applying a topcoat layer to said architectural material. 